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SERVICE WORK ON THE ENGINE

159

16.1

Checking the engine oil level

–

Raise the vehicle using the center stand. (

p. 76)

Danger

Danger of poisoning

 

Exhaust gases are poisonous and inhaling them may result

in unconsciousness and/or death.

–

When running the engine, always make sure there is sufficient ventilation,
and do not start or run the engine in an enclosed space without an effective
exhaust extraction system.

–

Start the engine and run it until it reaches operating temperature.

Six bars of the temperature display light up.

100622-10

–

Switch off the engine.

–

Unscrew oil dipstick

, wipe it off with a cloth and screw it back in all the way.

Unscrew the oil dipstick and read off the engine oil level.

The engine oil level must be between the

MIN

and the

MAX

marking on the dipstick.

» If the engine oil level is not at the specified level:

–

Add engine oil. (

p. 167)

–

Replace the oil dipstick.

Содержание 990 Adventure AUS

Страница 1: ...OWNER S MANUAL 2011 990 Adventure EU 990 Adventure AUS UK 990 Adventure R EU 990 Adventure R AUS UK 990 Adventure R FR Art no 3211657en...

Страница 2: ......

Страница 3: ...However it is never possible to exclude small deviations arising from further development in design and construction All specifications are non binding KTM Sportmotorcycle AG specifically reserves th...

Страница 4: ...s is permitted only with the express written permission of the copyright owner ISO 9001 12 100 6061 According to the international quality management standard ISO 9001 KTM uses quality assurance proce...

Страница 5: ...bination instrument display 26 Combination instrument speedometer 27 Setting kilometers or miles 27 Combination instrument time 28 Setting the clock 29 Combination instrument display ODO 29 Combinatio...

Страница 6: ...k absorber 74 SERVICE WORK ON THE CHASSIS 76 Raising the vehicle using the center stand 76 Raising the vehicle off of the center stand 77 Bleeding the fork legs 77 Cleaning the dust boots of the fork...

Страница 7: ...uses in the fuse box 130 Removing the headlight mask with the headlight 132 Installing the headlight mask with the headlight 134 Changing the low beam bulb 134 Changing the high beam bulb 135 Changing...

Страница 8: ...BLINK CODE 178 TECHNICAL DATA ENGINE 184 Capacity engine oil 185 Capacity coolant 185 TECHNICAL DATA ENGINE TIGHTENING TORQUES 186 TECHNICAL DATA CHASSIS 190 Lighting equipment 192 Tires 193 Capacity...

Страница 9: ...tanding In the interest of your own safety have these jobs performed by an authorized KTM workshop There your motorcycle will be serviced opti mally by specially trained experts using the specialist t...

Страница 10: ...such as very muddy or wet roads can lead to above average wear of components such as the transmission train or the brakes For this reason it may be necessary to service or replace worn parts before t...

Страница 11: ...ses Ex valve spring mounter 59029019000 During assembly non reusable parts e g self locking screws and nuts seals and seal rings O rings pins lock washers must be replaced by new parts Where thread lo...

Страница 12: ...ct with other persons Responsible behavior in handling the motorcycle can help to avoid such problems and con flicts To protect the future of motorcycle sport make sure that you use your motorcycle le...

Страница 13: ...amage if the appropriate measures are not taken Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken Owner s manual Be sure to read this owner s...

Страница 14: ...VIEW OF VEHICLE 12 3 1 View of vehicle front left side vehicle differs slightly from photo B00550 10...

Страница 15: ...ver p 19 2 Tool set p 44 3 Seat lock p 37 4 Luggage rack plate p 40 5 Handrails p 39 6 Fork compression adjustment 7 Fuel taps p 40 8 Side stand p 42 9 Shift lever p 41 10 Footrest 11 Center stand p 4...

Страница 16: ...VIEW OF VEHICLE 14 3 2 View of vehicle rear right side vehicle differs slightly from photo B00551 10...

Страница 17: ...er switch p 20 3 Hazard warning flasher switch hazard warning flasher p 34 4 Socket for electrical accessories p 34 5 Emergency OFF switch p 23 5 Electric starter button p 23 6 Hand brake lever p 19 7...

Страница 18: ...100542 10 The chassis number is stamped on the right side of the steering head The chassis number is also found on the type label 4 2 Type label 100543 10 The type label is located on the right frame...

Страница 19: ...700222 01 The key number Code number can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place Use the orange programming key to activate...

Страница 20: ...5 Fork part number 100545 10 The fork part number is stamped on the inner side of the fork stub 4 6 Shock absorber part number 100546 10 The shock absorber part number is stamped on the upper part of...

Страница 21: ...er is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 5 2 Hand brake lever 100506 10 The hand brake lever is fitted on the right side of the handlebar...

Страница 22: ...ight are switched on High beam on The light switch is turned upwards In this position the high beam and tail light are switched on 5 4 Headlight flasher switch 100508 10 The headlight flasher switch i...

Страница 23: ...to the central position after use Turn signal right on The turn signal switch is pressed to the right The turn signal switch automatically returns to the central position after use To switch off the t...

Страница 24: ...n circuit is closed and the engine can be started Steering locked In this position the ignition circuit is interrupted and the steering locked The black ignition key can be removed 5 8 Immobilizer 400...

Страница 25: ...The emergency OFF switch is fitted on the right side of the handlebar Possible states Emergency OFF switch off In this position the ignition circuit is inter rupted a running engine stops and the engi...

Страница 26: ...5 12 Combination instrument function buttons 400914 10 You can change the display mode with the MODE button Possible display modes are the distance traveled ODO trip master 1 TRIP 1 trip mas ter 2 TRI...

Страница 27: ...he motorcy cle Possible states The turn signal indicator lamp flashes green simultaneously with the turn signal The turn signal is switched on The idle speed indicator lamp lights up green The transmi...

Страница 28: ...r lamp lights up or flashes red Status or error message for immobilizer alarm system The battery warning lamp lights up red The voltage in the vehicle system is too low 990 Adventure The ABS warning l...

Страница 29: ...ront wheel with a series production tire The display then changes to the last selected mode 5 16 Combination instrument speedometer 400838 10 The speed is shown in kilometers per hour km h or in miles...

Страница 30: ...on ON Press the MODE button repeatedly until the ODO mode is active Keep the MODE button pressed until the display mode changes from km h to mph or from mph to km h 5 18 Combination instrument time 40...

Страница 31: ...he SET button pressed simultaneously The time display begins to flash Press the MODE button to set the hour Press the SET button to set the minute Keep the MODE button and the SET button pressed simul...

Страница 32: ...400840 01 Switch on the ignition by turning the black ignition key to the position ON Press the MODE button repeatedly until the TRIP 1 mode is active Keep the SET button pressed The TRIP 1 display is...

Страница 33: ...s active Keep the SET button pressed The TRIP 2 display is set to 0 0 5 23 Combination instrument TRIP F display 400842 01 If the fuel level drops to the reserve mark the display automatically changes...

Страница 34: ...25 Setting the temperature unit of measure Condition The motorcycle is standing 400893 14 Switch on the ignition by turning the black ignition key to the position ON Press the MODE button repeatedly...

Страница 35: ...isplay when the ambient temperature rises above the specified value again Temperature 4 C 39 F 5 27 Combination instrument coolant temperature indicator 400617 01 The temperature display consists of 1...

Страница 36: ...ning flasher switch is found to the left of the combination instrument The hazard warning flasher is used to indicate emergency situations Info The hazard warning flasher can be activated or deactivat...

Страница 37: ...er and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc tor immediately Change clothing that has come into contact with fuel Store fuel in a...

Страница 38: ...are equipped with a ventilation system 5 31 Closing the filler caps 100515 10 Warning Fire hazard Fuel is highly flammable poisonous and harmful to your health When closing the filler cap ensure that...

Страница 39: ...and locks and unlocks the storage compartment Possible states Storage compartment locked Storage compartment unlocked Seat unlocked The seat lock can be locked with the ignition key 5 33 Unlocking the...

Страница 40: ...Turn the ignition key to position Remove the ignition key 5 35 Opening the storage compartment 100520 10 Unlock the storage compartment p 37 Press button toward the seat and raise the cover at the sa...

Страница 41: ...y engages Info The storage compartment can be opened again as long as it has not been locked using the seat lock Lock the storage compartment p 38 5 37 Handrails B00553 10 The handrails are used for m...

Страница 42: ...ation provided by the luggage manufacturer 5 39 Fuel taps 100524 10 There is a fuel tap on every fuel tank Info The fuel taps must be open during operation The fuel taps are only closed when dismantli...

Страница 43: ...ot brake lever 100525 10 Foot brake lever is located in front of the right footrest The rear brake is activated using the foot brake lever 5 41 Shift lever 100526 10 Shift lever is mounted on the left...

Страница 44: ...e vehicle The side stand is used for parking the motorcycle Info The side stand must be folded up during motorcycle use Side stand is coupled with the safety start system see the riding instructions P...

Страница 45: ...center stand in addition to a side stand 5 44 Passenger footrests 100530 10 The passenger footrests can be folded up and down Possible states Passenger footrests folded up For operation without a pas...

Страница 46: ...CONTROLS 44 5 45 Tool set 100531 10 The tool set is located in the storage compartment under the seat The extension can be mounted on several of the wrenches in the tool set...

Страница 47: ...ashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control ov...

Страница 48: ...ervice record at vehicle handover Before your first trip read the entire operating instructions carefully Get to know the controls Adjust the basic setting of the clutch lever p 95 Adjust the free tra...

Страница 49: ...lmet baggage Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and or tank rucksack Mount and secure suitcase and tank rucksack according to the manuf...

Страница 50: ...ble handling characteristics due to slipped baggage Check the way your baggage is fixed regularly Warning Danger of burns A hot exhaust system can burn baggage Fasten your baggage in such a way that i...

Страница 51: ...vel p 105 Check the front brake linings p 104 Check the rear brake linings p 108 Check that the brake system is functioning properly Check the coolant level in the compensating tank p 154 Check the ch...

Страница 52: ...in an enclosed space without an effective exhaust extraction system Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic components and safe...

Страница 53: ...lectric starter button Info Do not press the electric starter button until the function test of the combination instrument is finished When starting DO NOT open the throttle If you open the throttle d...

Страница 54: ...owly and simultaneously open the throttle carefully 7 4 Shifting riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control Avoid abrupt load alterations an...

Страница 55: ...er early on Warning Danger of accidents Reduced road grip with cold tires On every journey take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road...

Страница 56: ...the engine Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear Note Engine failure Overheating of engine If the coolant temperature wa...

Страница 57: ...to a speed suitable for the road surface and weather conditions When traveling in bends do not shift and accelerate very carefully To shift down brake if necessary and close the throttle at the same...

Страница 58: ...drag continuously The rear brake may fail due to overheating Take your foot off the foot brake lever when you are not braking Warning Danger of accidents Longer stopping distance due to higher overal...

Страница 59: ...ry surface Warning Danger of accidents Road grip is reduced when braking with the motorcycle at an angle or on a laterally inclined surface Braking should be completed before you enter into a bend Bra...

Страница 60: ...t when the vehicle is operated Do not touch hot components such as exhaust system radiator engine shock absorber and brakes Allow these components to cool down before starting work on them Note Danger...

Страница 61: ...ion OFF Info If you switch off the engine with the emergency OFF switch but the ignition remains switched on at the ignition lock power continues to flow to most power consumers and the battery is soo...

Страница 62: ...tor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc tor immediately Change clothing that has come into contact with fuel Note Material damage Premature clog...

Страница 63: ...5 3 US gal Super unleaded ROZ 95 RON 95 PON 91 p 206 Info If the right fuel tank is filled to the filler neck fuel may flow out if the vehicle is resting on the side stand and the fuel heats up Close...

Страница 64: ...s the SET button for two seconds The fuel level warning lamp switches off TRIP F is set to 0 0 and appears in the previous display mode Info If you do not press the SET button the reset takes place au...

Страница 65: ...e linings p 108 Check the brake discs p 100 Check that the brake lines are undamaged and free of leaks Check the rear brake fluid level p 105 Check the free travel of the foot brake lever p 104 Check...

Страница 66: ...ifreeze and coolant level p 147 Check the wiring harness of the throttle valve body for damage and correct routing x Check the cables for damage and kink free routing x Check the control cables for da...

Страница 67: ...e vehicle is roadworthy and take a test ride Read out the error memory after the test ride using the KTM diagnostics tool x Make the necessary service entries in the KTM DEALER NET and service record...

Страница 68: ...ersonal suspension adaptation Do not change the adjustments at random or by more than 40 since otherwise the riding characteristics could deteriorate particularly at high speeds 9 2 Adjusting the comp...

Страница 69: ...cks 990 Adventure R Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping Moun...

Страница 70: ...s Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline 990 Adventure Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Full payload 13 clicks...

Страница 71: ...e adjustment on both fork legs Turn back clockwise by the number of turns corresponding to the fork type Guideline 990 Adventure Spring preload Preload Adjuster Comfort 5 turns Standard 5 turns Sport...

Страница 72: ...the landing after a jump the rear wheel suspension compresses more quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses mor...

Страница 73: ...clicks corresponding to the shock absorber type Guideline 990 Adventure Compression damping low speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks 990 Adventure R Compr...

Страница 74: ...vided Your authorized KTM workshop will be glad to help Info The high speed setting can be seen during the fast compression of the shock absorber 100538 10 Turn adjusting screw clockwise all the way u...

Страница 75: ...d damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provid...

Страница 76: ...licks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 9 9 Adjusting the spring preload of the shock absorber Caution Danger of ac...

Страница 77: ...e 990 Adventure Spring preload Preload Adjuster Comfort 4 turns Standard 4 turns Sport 8 turns Full payload 16 turns 990 Adventure R Spring preload Preload Adjuster Comfort 4 turns Standard 4 turns Sp...

Страница 78: ...le it is resting on the center stand The center stand or frame could be damaged and the motorcycle could fall over Pull the motorcycle up onto the center stand using the handrail and not the handwheel...

Страница 79: ...ward with both hands on the handlebar As the vehicle moves off of the center stand activate the front brake to prevent the vehicle from rolling Check that the center stand is folded all the way up 10...

Страница 80: ...braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Clean and oil the dust boots and inner f...

Страница 81: ...position Move the fork legs back and forth in the direction of travel Play should not be detectable on the steering head bearing If there is no detectable play Adjust the steering head bearing play x...

Страница 82: ...ont side cover Info The operations are the same on the left and right sides 100589 11 Position side cover at the fuel tank on the bottom and hold it at an angle Attach the overflow hose of the fuel ta...

Страница 83: ...the radiator guard 100641 10 Remove screws and radiator guard 100642 10 Pull nuts off of the radiator Tip Insert the screws into the holes of the radiator guard and mount the nuts This ensures that a...

Страница 84: ...ator Hook radiator guard into holes at the bottom and swing up to the radiator Mount and tighten screws Guideline Remaining chassis nuts M6 15 Nm 11 1 lbf ft 10 10 Removing the seat 100516 10 Insert t...

Страница 85: ...g pin into the lock housing and push the back of the seat down until the locking pin locks in place with an audible click Finally check that the seat is correctly mounted 10 12 Removing the storage co...

Страница 86: ...Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health h...

Страница 87: ...t detach from the upper holder and swing the top away from the vehicle Info Hold the fuel tank at about the same height as when it is mounted Before removing the fuel tank entirely a number of hoses a...

Страница 88: ...ng Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc t...

Страница 89: ...the front side cover p 80 Turn the knurled screws on both fuel taps counterclockwise as far as possible Check the fuel system for leaks 10 16 Checking for chain dirt 400678 01 Check the chain for coar...

Страница 90: ...l hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info The service life of the cha...

Страница 91: ...On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check the chain tension and correct if necessary 0 0 B B...

Страница 92: ...sprocket rear sprocket bearings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can br...

Страница 93: ...nd right chain adjuster are in the same position in relation to reference marks The rear wheel is then correctly aligned Info The upper chain section must be taut Chain wear is not always even so you...

Страница 94: ...cket and engine sprocket 100132 10 Check the rear sprocket and engine sprocket for wear If the rear sprocket or engine sprocket is worn Change the rear sprocket or engine sprocket x Info The rear spro...

Страница 95: ...of 18 chain links in the lower chain section Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance at the longest chain section 272 mm...

Страница 96: ...ss If the chain sliding guard is loose Fully tighten the chain sliding guard Guideline Screw chain sliding guard M6 6 Nm 4 4 lbf ft Loctite 243 B00114 01 Check the chain guide for wear If the chain gu...

Страница 97: ...ustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 10 22 Checking rectifying the fluid level of the hydraulic clutch Info The...

Страница 98: ...ighten the screws 10 23 Removing the right underride guard 100581 10 Remove screws Remove the right underride guard 10 24 Installing the right underride guard 100581 11 Position right underride guard...

Страница 99: ...10 Swing the side stand downward Remove all four screws and take off underride guard 10 26 Installing the underride guard x 100578 10 Position underride guard Mount and tighten screws Guideline Screw...

Страница 100: ...that prevents locking of the wheels when traveling straight ahead without the action of lateral forces ABS works with two mutually independent brake circuits front and rear brake Under nor mal conditi...

Страница 101: ...d brake lever Warning Danger of accidents Brake system failure If there is no free travel on the hand brake lever pressure builds up in the front brake circuit The front brake can fail due to overheat...

Страница 102: ...ndlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 11 4 Checking the brake discs Warning Danger of acc...

Страница 103: ...fluid level Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the b...

Страница 104: ...gs Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin...

Страница 105: ...d for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 100558 10 Move the brake fluid reservoir mounte...

Страница 106: ...le Check the brake linings regularly 100559 10 Check all brake linings on both brake calipers to ensure they have minimum thick ness Minimum thickness 1 mm 0 04 in If the minimum thickness is less tha...

Страница 107: ...meet specifications Adjust the basic position of foot brake lever x 11 9 Checking the rear brake fluid level Warning Danger of accidents Failure of the brake system If the brake fluid level falls bel...

Страница 108: ...brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and...

Страница 109: ...able regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painte...

Страница 110: ...ger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help Note Danger of accidents Reduced brakin...

Страница 111: ...s for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings x Check the brake linings for damage and cracking If there is wear...

Страница 112: ...the rear of the vehicle or raise it on the underride guard The front wheel is not in contact with the ground 100605 10 Press the brake calipers by hand on to the brake discs in order to press back the...

Страница 113: ...accidents Reduced braking efficiency caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not dam aged Holding the front wheel withdraw the wheel spindle Swin...

Страница 114: ...earing x Clean and grease the shaft seal rings and bearing surface of the spacers Long life grease p 208 Insert the spacers 100604 11 Lift the front wheel into the fork engage the brake discs into the...

Страница 115: ...wheel speed sensor and push them into the hole together Mount and tighten screw Guideline Screw connection wheel speed sensor front M6 6 Nm 4 4 lbf ft 12 3 Removing the rear wheel x Raise the vehicle...

Страница 116: ...wheel spindle only far enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Take the chain off of the rear sprocket and place it on chain sprocket guard...

Страница 117: ...grease and clean them with brake cleaner when necessary Warning Danger of accidents No braking effect when operating the rear brake After installing the rear wheel always operate the foot brake until...

Страница 118: ...e rear wheel forward so that the chain adjusters are in contact with the adjust ing screws and tighten nut Guideline In order for the rear wheel to be correctly aligned the markings on the left and ri...

Страница 119: ...mpers of the rear hub for damage and wear If the rubber dampers of the rear hub are damaged or worn Change all rubber dampers in the rear hub 100573 10 Lay the rear wheel on a workbench with the rear...

Страница 120: ...trollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Warning Danger of acci...

Страница 121: ...res Info The tire s date of manufacture is usually part of the tire markings and is indi cated by the last four digits of the DOT marking The first two digits refer to the week of manufacture and last...

Страница 122: ...meet specifications Correct the tire pressure Mount the dust cap 12 8 Checking spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that the spoke tension...

Страница 123: ...frequency of the sound is a function of the spoke length and spoke diame ter If spokes of the same length and diameter vibrate with a different tone this is an indication that the spoke tensions diff...

Страница 124: ...ontact with battery acid and battery gases Keep the battery away from sparks or open fire Charge only in well ventilated rooms Flush with copious amounts of water in case of skin contact If battery ac...

Страница 125: ...ery tray Info Never operate the motorcycle with a discharged battery or without a battery In both cases electrical components and safety equipment can be damaged The vehicle is then no longer safe to...

Страница 126: ...ith battery acid and battery gases Keep the battery away from sparks or open fire Charge only in well ventilated rooms Flush with copious amounts of water in case of skin contact If battery acid comes...

Страница 127: ...through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharg...

Страница 128: ...at tery and to test the generator With this device you cannot overcharge the battery Switch off and disconnect the charger after charging Guideline Charge the battery regularly when the motorcycle is...

Страница 129: ...guard p 96 100583 10 Pull starter relay off of the holder and remove protective cover 100584 10 990 Adventure Remove the faulty main fuse Info A defective fuse can be identified by the burned out fuse...

Страница 130: ...e fuse in the starter relay so that it is available if needed Install the right underride guard p 96 Set the clock p 29 13 5 Changing the ABS fuses 990 Adventure Warning Fire hazard The electrical sys...

Страница 131: ...1109125 p 191 Check whether the ABS warning lamp is still lit Mount the protective cover Tip Place the spare fuse in the storage compartment so that it is available if needed 100586 10 Changing the fu...

Страница 132: ...ox Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses Use only fuses with the prescribed amperage Never by pass or repair fuses Info The fuse box containing the...

Страница 133: ...e POWER RELAY 10 A ignition EFI control unit Fuse ACC1 CLOCK 10 A combination instrument socket supplementary devices permanent positive alarm system optional Fuse ACC2 10 A supplementary equipment ac...

Страница 134: ...91 Fuse 58011109115 p 191 Info Spare fuses are located next to the fuse box Tip Replace the spare fuse in the fuse box so that it is available if needed Check that the power consumers are functioning...

Страница 135: ...10 Unhook the headlight mask from the cockpit holder and remove it toward the front 100591 10 Disconnect plug in connector Place the headlight mask down on a soft cloth to prevent the headlight and t...

Страница 136: ...headlight mask Install the front side cover p 80 Check the headlight setting p 140 13 9 Changing the low beam bulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to...

Страница 137: ...nfo The bulb must be positioned with projection in the recess Attach the connector to the bulb and mount the rubber cap Install the headlight mask with the headlight p 134 13 10 Changing the high beam...

Страница 138: ...fo The bulb must be correctly seated at projections Connect the plug in connector and mount the rubber cap Install the headlight mask with the headlight p 134 13 11 Changing the parking light bulb in...

Страница 139: ...ance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting 100597 10 Remove the screw on the rear of the turn si...

Страница 140: ...ockwise until it engages in the thread Tighten the screw slightly 13 13 Changing the tail light bulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be...

Страница 141: ...unction Position the tail light Mount and tighten the nuts with the washers Guideline Nut tail light M6 8 Nm 5 9 lbf ft 13 14 Changing the brake light bulb Note Damage to reflector Reduced luminance G...

Страница 142: ...n Position the tail light Mount and tighten nuts with the washers Guideline Nut tail light M6 8 Nm 5 9 lbf ft 13 15 Checking the headlight setting 0 0 A A 0 0 B B 400609 10 Park the vehicle on a horiz...

Страница 143: ...Info Turn clockwise to increase the light range turn counterclockwise to reduce the light range If you have a heavy payload you will need to correct the headlight range 13 17 Activating deactivating...

Страница 144: ...up Switch off the ignition by turning the orange programming key to the OFF position Pull out the programming key Insert the black ignition key in the ignition lock Switch on the ignition by turning...

Страница 145: ...y Turn the emergency OFF switch to the position 400919 10 Insert the orange programming key in the ignition lock Switch on the ignition by turning the orange programming key to the ON position FI Warn...

Страница 146: ...itch off the ignition by turning the orange programming key to the OFF position Pull out the programming key Insert the black ignition key in the ignition lock Switch on the ignition by turning the bl...

Страница 147: ...mber of flashes equals the number of functional black ignition keys includ ing the orange programming key Switch off the ignition by turning the orange programming key to the OFF position Pull out the...

Страница 148: ...ature without causing any malfunctions 125 C 257 F 0 0 2 2 0 0 3 3 400619 10 Cooling takes place by means of the air stream and a radiator fan which is controlled by a thermoswitch The lower the speed...

Страница 149: ...r cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poi...

Страница 150: ...coolant level in the compensating tank The coolant level must be between MIN and MAX If there is no coolant in the compensating tank Check the cooling system for leaks x Info Do not start up the motor...

Страница 151: ...st be completely filled If the coolant level does not meet specifications Coolant loss 0 50 l 0 53 qt Check the cooling system for leaks x Info Do not start up the motorcycle Correct the coolant level...

Страница 152: ...cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it...

Страница 153: ...ew with a new seal ring and tighten it Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft 14 4 Filling bleeding the cooling system x Warning Danger of poisoning Coolant is poisonous and a health haz...

Страница 154: ...ove bleeder screw 0 0 A A 400663 10 Position the vehicle as shown and secure it against rolling Height difference must be reached Guideline Height difference 50 cm 19 7 in Info To make sure that all o...

Страница 155: ...ean the vehicle on the side stand Check the coolant level in the compensating tank p 154 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or d...

Страница 156: ...diator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of pois...

Страница 157: ...mpensating tank Check the cooling system for leaks x Info Do not start up the motorcycle Fill bleed the cooling system x p 151 If the coolant in the compensating tank is not at the required level but...

Страница 158: ...lay in the throttle cable x p 157 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is...

Страница 159: ...nector 100554 10 Plug in connector is located under the seat close to where the top of the shock absorber is attached By disconnecting the plug in connector the ignition curve for fuel with an octane...

Страница 160: ...below 95 ROZ 95 RON 95 PON 91 for no more than one tank full The ignition curve must be adjusted to low octane fuel Disconnect plug in connector Figure 100554 10 p 157 Plug in connector disconnected...

Страница 161: ...ne in an enclosed space without an effective exhaust extraction system Start the engine and run it until it reaches operating temperature Six bars of the temperature display light up 100622 10 Switch...

Страница 162: ...creens x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lu...

Страница 163: ...rews and cover Pull oil screen out of the engine case with pliers 100625 10 Remove screw on the right fuel tank and remove screws Take off bracket 100626 10 Raise the vehicle off of the center stand p...

Страница 164: ...ean all sealing surfaces 100628 10 Check seal ring of the oil sieve for damage and correct seating Insert oil sieve into the oil tank Position the oil line Mount and tighten the screws Guideline Remai...

Страница 165: ...Mount and tighten the screws Guideline Screw clutch cover M6 10 Nm 7 4 lbf ft 100625 10 Position bracket Mount and tighten screws Guideline Remaining chassis screws M8 25 Nm 18 4 lbf ft Mount and tigh...

Страница 166: ...ed of as stipulated in applicable regulations Condition The underride guard has been removed Place a suitable container under the engine 100632 10 Remove screws Take off oil filter cover with the O ri...

Страница 167: ...Filling up with engine oil x Info Too little engine oil or poor quality engine oil results in premature wear to the engine 100622 10 The oil must be added in two steps Engine oil 3 0 l 3 2 qt Externa...

Страница 168: ...ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and run it until it reaches operating temperature Six bars of the t...

Страница 169: ...hen the engine is warm 100622 10 Remove oil dipstick and add engine oil to the MAX marking Condition External temperature 0 C 32 F Engine oil SAE 10W 50 p 204 Condition External temperature 0 C 32 F E...

Страница 170: ...id etc should be disposed of as stipulated in applicable regulations Info If you clean the motorcycle regularly its value and appearance are maintained over a long period Avoid direct sunshine on the...

Страница 171: ...casionally Info The heat produced causes water at inaccessible positions in the engine and on the brakes to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean...

Страница 172: ...water Warm water would enhance the corrosive effects of salt 401060 01 Clean the motorcycle p 168 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with a wax ba...

Страница 173: ...as empty as possible so that you can fill up with fresh fuel when you put the motorcycle back into operation Clean the motorcycle p 168 Change the engine oil and filter clean the oil screens x p 160...

Страница 174: ...t warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 18 2 Preparing for use after storage 401059 01 Raise the vehicle off of the center...

Страница 175: ...t x Malfunction in CAN bus communica tion Check the CAN bus communication x Combination instrument defective Check the combination instrument x Control unit for electric start lock defective Check the...

Страница 176: ...the coolant x p 150 Fill bleed the cooling system x p 151 Buckled or damaged radiator hose Change the radiator hose x Fuse FAN blown Change the fuses in the fuse box p 130 Thermostat defective Check t...

Страница 177: ...hange the fuses in the fuse box p 130 Turn signal hazard warning flasher brake light and horn are not functional Fuse HORN BRAKE LIGHT blown Change the fuses in the fuse box p 130 Battery discharged I...

Страница 178: ...trol unit Blink code of immobilizer indica tor lamp 14 Immobilizer indicator lamp flashes 1x short 1 second pause 4x short Error level condition Malfunction in transponder of black ignition key Blink...

Страница 179: ...indicator lamp flashes 3x short 1 second pause 1x short Error level condition Malfunction encryption query from EFI control unit to immobilizer control unit Blink code of immobilizer indica tor lamp 3...

Страница 180: ...lamp FI MIL flashes 7x short Error level condition Throttle position sensor circuit B input signal too low Throttle position sensor circuit B input signal too high Flash code of warning lamp FI MIL 09...

Страница 181: ...ke air temperature sensor input signal too high Flash code of warning lamp FI MIL 14 Warning lamp FI MIL flashes 1x long 4x short Error level condition Ambient air pressure sensor input signal too low...

Страница 182: ...dition Power supply malfunction in circuit Flash code of warning lamp FI MIL 25 Warning lamp FI MIL flashes 2x long 5x short Error level condition Side stand circuit fault Flash code of warning lamp F...

Страница 183: ...rt Error level condition Fuel pump control interruption short circuit to ground Fuel pump control input signal too high Flash code of warning lamp FI MIL 45 Warning lamp FI MIL flashes 4x long 5x shor...

Страница 184: ...ning lamp FI MIL 54 Warning lamp FI MIL flashes 5x long 4x short Error level condition Secondary air valve interruption short circuit to ground Secondary air valve input signal too high Flash code of...

Страница 185: ...FI MIL 81 Warning lamp FI MIL flashes 8x long 1x short Error level condition Immobilizer control unit malfunction in circuit Flash code of warning lamp FI MIL 91 Warning lamp FI MIL flashes 9x long 1x...

Страница 186: ...e clearance Exhaust at 20 C 68 F 0 25 0 30 mm 0 0098 0 0118 in Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Crankshaft bearing Sleeve bearing Conrod bearing Sleeve bearing Piston Forged light all...

Страница 187: ...450 W Spark plug NGK LKAR8BI9 Spark plug electrode gap 0 8 mm 0 031 in Cooling Water cooling permanent circulation of coolant by water pump Cold start device Electric starter 22 1 Capacity engine oil...

Страница 188: ...10 Nm 7 4 lbf ft Screw in alternator cover M6 10 Nm 7 4 lbf ft Screw bearing bolt in alternator cover M6 10 Nm 7 4 lbf ft Loctite 243 Screw camshaft bearing support M6 10 Nm 7 4 lbf ft Screw clutch c...

Страница 189: ...g chain guide rail M8 15 Nm 11 1 lbf ft Loctite 243 Bearing bolt timing chain tensioning rail M8 20 Nm 14 8 lbf ft Loctite 243 Screw camshaft bearing support M8 Step 1 10 Nm 7 4 lbf ft Step 2 18 Nm 13...

Страница 190: ...12 Nm 8 9 lbf ft Plus cylinder head 2nd cylinder M12x1 5 25 Nm 18 4 lbf ft Plug oil filter housing M14x1 5 15 Nm 11 1 lbf ft Loctite 243 Bleeder flange alternator cover M16x1 5 10 Nm 7 4 lbf ft Locti...

Страница 191: ...TECHNICAL DATA ENGINE TIGHTENING TORQUES 189 Nut primary gear M33LHx1 5 130 Nm 95 9 lbf ft Loctite 243...

Страница 192: ...in Suspension travel 990 Adventure R Rear 245 mm 9 65 in Brake system Front Double disk brake with floating brake calipers and brake discs Rear Single disc brake with floating brake caliper and brake...

Страница 193: ...ded 990 Adventure R 905 mm 35 63 in Ground clearance unloaded 990 Adventure 261 mm 10 28 in Ground clearance unloaded 990 Adventure R 301 mm 11 85 in Weight without fuel approx 990 Adventure 209 kg 46...

Страница 194: ...PX26d 12 V 55 W High beam H3 socket PK22s 12 V 55 W Parking light W5W socket W2 1x9 5d 12 V 5 W Instrument lights and indicator lamps LED Turn signal RY10W socket BAU15s 12 V 10 W Tail light WR5W soc...

Страница 195: ...A T 90 90 21 M C 54S M S TT Continental TKC 80 150 70 B 18 M C 70Q M S TT Continental TKC 80 Alternative tires to max 160 km h 99 4 mph Additional information is available in the Service section under...

Страница 196: ...ull payload 10 clicks Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Full payload 13 clicks Spring preload Preload Adjuster Comfort 5 turns Standard 5 turns Sport 8 turns Full pa...

Страница 197: ...Up Side Down 4860 MXMA PA Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Full pay...

Страница 198: ...TA FORK 196 Medium standard 4 8 N mm 27 4 lb in Hard 5 0 N mm 28 6 lb in Fork length 915 mm 36 02 in Air chamber length 100 30 20 mm 3 94 1 18 0 79 in Fork oil per fork leg 660 ml 22 31 fl oz Fork oil...

Страница 199: ...t 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Rebound damping Comfort 20 clic...

Страница 200: ...5 in Shock absorber oil p 205 SAE 2 5 26 2 990 Adventure R Shock absorber part number 12 18 7K 09 Shock absorber WP Suspension PDS 5018 DCC PA Compression damping low speed Comfort 25 clicks Standard...

Страница 201: ...omfort 4 turns Standard 4 turns Sport 8 turns Full payload 10 turns Spring rate Soft 130 N mm 742 lb in Medium standard 140 N mm 799 lb in Hard 150 N mm 857 lb in Spring length 225 mm 8 86 in Gas pres...

Страница 202: ...6 4 Nm 3 lbf ft Nut tail light M6 8 Nm 5 9 lbf ft Remaining chassis nuts M6 15 Nm 11 1 lbf ft Remaining chassis screws M6 10 Nm 7 4 lbf ft Screw connection wheel speed sensor front M6 6 Nm 4 4 lbf ft...

Страница 203: ...18 4 lbf ft Screw bottom triple clamp M8 15 Nm 11 1 lbf ft Screw exhaust clamp M8 8 Nm 5 9 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw...

Страница 204: ...9 lbf ft Loctite 243 Screw subframe M10x1 25 45 Nm 33 2 lbf ft Loctite 243 Oil drain plug with magnet M12x1 5 25 Nm 18 4 lbf ft Screw bottom shock absorber M14x1 5 80 Nm 59 lbf ft Thread greased Screw...

Страница 205: ...products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant also in countries with high temperatures Use of low quality antifree...

Страница 206: ...responding properties KTM recommends Motorex products Fully synthetic engine oil Supplier Motorex Power Synt 4T Engine oil SAE 5W 40 According to JASO T903 MA p 209 SAE p 209 SAE 5W 40 Guideline Use o...

Страница 207: ...ic fluid 15 According to ISO VG 15 Guideline Use only hydraulic oil that complies with the specified standard see specifications on the container and that possesses the corre sponding properties KTM r...

Страница 208: ...SUBSTANCES 206 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91...

Страница 209: ...or road use Guideline KTM recommends Motorex products Supplier Motorex Chainlube Road Cleaning and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Supplier...

Страница 210: ...recommends Motorex products Supplier Motorex Bike Grease 2000 Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Universal oil spray Guideline KTM recommends...

Страница 211: ...e intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with...

Страница 212: ...hanging 139 Brake linings front brake checking 104 rear brake checking 108 Brakes 56 Braking 56 C Center stand 43 Chain checking 92 checking for dirt 87 cleaning 87 Chain tension adjusting 90 checking...

Страница 213: ...FF switch 23 Engine running in 46 Engine number 17 Engine oil adding 167 changing 160 draining 160 refilling 165 Engine oil level checking 159 Engine sprocket checking 92 Environment 10 F Filler caps...

Страница 214: ...eadlight flasher switch 20 Headlight mask with headlight installing 134 removing 132 High beam bulb changing 135 Horn button 21 I Ignition curve adjusting to fuel quality 158 plug in connector 157 Ign...

Страница 215: ...82 removing 81 Rear hub rubber dampers checking 117 Rear sprocket checking 92 Rear wheel installing 115 removing 113 Riding 52 starting off 52 S Seat mounting 83 removing 82 Seat lock 37 Service 8 Se...

Страница 216: ...193 chassis tightening torques 200 202 engine 184 185 engine tightening torques 186 189 fork 194 196 shock absorber 197 199 Tire air pressure checking 119 Tire condition checking 118 Tool set 44 Trans...

Страница 217: ...INDEX 215 View of vehicle front left side 12 rear right side 14 W Warning of slippery roads 33 Warranty 8 Work rules 9...

Страница 218: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 09 2010 Photo Mitterbauer 3211657en 3211657en...

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